Three-pass torque converter having multiple flow passages

ABSTRACT

A torque converter comprising a cover arranged to receive torque, an impeller having an impeller shell non-rotatably connected to the cover, and a turbine in fluid communication with the impeller and including a turbine shell is provided. In embodiments, the torque converter includes a lock-up clutch including a piston plate, an output hub connected to the turbine shell and arranged to non-rotatably connect to a transmission input shaft, and a seal plate disposed, at least partially, axially between the piston plate and the turbine shell, wherein the seal plate is connected to the cover and the piston plate. A flow plate may be connected to the seal plate and disposed axially between the seal plate and the turbine shell. A through-bore may be bounded in first and second opposite radial directions by the seal plate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/977,120 filed Feb. 14, 2020, the entire disclosure of which is incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates generally to torque converters and more specifically to torque converters having multiple flow passages to supply fluid to pressure chambers.

BACKGROUND

Many vehicles include a launch device between the engine and the transmission. A torque converter is a type of launch device commonly used in vehicles having an automatic transmission. A typical torque converter includes an impeller fixed to the crankshaft of the engine and a turbine fixed to a turbine shaft, which is the input to the transmission. To improve fuel economy, most torque converters include a bypass or lock-up clutch that mechanically couples the turbine shaft to a case of the torque converter to bypass the fluid coupling. Torque converters may have multiple flow passages for clutch apply and release. It is known to use cross-flow hubs for providing flow paths for clutch apply and release pressure chambers. However, these cross-flow hubs may be expensive and add complexity to a torque converter design. Accordingly, it is desirable to provide alternative methods for providing fluid flow paths to pressurized chambers of a torque converter.

SUMMARY

Embodiments of this disclosure provide a torque converter comprising a cover arranged to receive torque, an impeller having an impeller shell non-rotatably connected to the cover, and a turbine in fluid communication with the impeller and including a turbine shell. In embodiments, the torque converter includes a lock-up clutch including a piston plate, an output hub connected to the turbine shell and arranged to non-rotatably connect to a transmission input shaft, and a seal plate disposed, at least partially, axially between the piston plate and the turbine shell, wherein the seal plate is connected to the cover and the piston plate. A flow plate may be connected to the seal plate and disposed axially between the seal plate and the turbine shell. A through-bore may be bounded in first and second opposite radial directions by the seal plate, wherein a first chamber is bounded at least in part by the piston plate and the seal plate and a second chamber is bounded at least in part by the cover, the seal plate, and the piston plate. In embodiments, a rivet connects the seal plate with the flow plate and the through-bore is defined within the rivet.

In embodiments, a first flow path may be configured to provide fluid to the first chamber, wherein the first flow path includes a portion bounded in part by the seal plate and the flow plate. A second flow path may be configured to provide fluid to the second chamber, wherein the second flow path passes through the through-bore and includes a portion bounded in part by the flow plate and the output hub. In embodiments, the first flow path is sealed from the second flow path and the first flow path does not pass through the through-bore. The seal plate may also include an opening extending axially therethrough and the first flow path passes through the opening into the first chamber, which may be radially outside of the through-bore. Moreover, the output hub may include an opening extending axially therethrough and the second flow path passes through the opening.

In embodiments, for a lock-up mode the piston plate is non-rotatably connected to the cover and pressurized fluid is arranged to flow through the first flow path into the first chamber to displace the piston plate in an axial direction toward the cover. In other embodiments, for a torque converter mode pressurized fluid is arranged to flow through the second flow path passing through the through-bore into the second chamber to displace the piston plate in an axial direction away from the cover to disconnect the piston plate from the cover. In embodiments, an inner end of the cover is connected to the seal plate and the seal plate is further connected to the piston plate at an outer diameter thereof.

Embodiments disclosed herein provide the advantageous benefit of reduced costs and complexity of three-pass torque converters, for example, by removing a hub that is typically used to direct flow to appropriate apply and cooling circuits. Furthermore, embodiments disclosed herein offer design advantages by creating a cross-flow configuration without any forgings or costly cross drilling operations. Moreover, embodiments disclosed herein allow for use of a twin plate clutch design, which requires higher clutch load.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a torque converter configured for cross flow to pressure chambers according to an embodiment of the present disclosure.

FIG. 2 is an enlarged view of an area of the torque converter shown in FIG. 1 showing cross flow to pressure chambers.

DETAILED DESCRIPTION

Embodiments of the present disclosure are described herein. It should be appreciated that like drawing numbers appearing in different drawing views identify identical, or functionally similar, structural elements. Also, it is to be understood that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

FIG. 1 shows a torque converter 100 in accordance with an embodiment of the present disclosure. FIG. 2 shows an enlarged view of an area of torque converter 100 showing cross flow into pressure chambers. The following description is made with reference to FIGS. 1-2. Torque converter 100 includes: axis of rotation AR; cover 102 arranged to receive torque; impeller 104; turbine 106; lock up clutch 108; output hub 110; flow plate 112; and seal plate 114 non-rotatably connected to cover 102. Impeller 104 includes: impeller shell 116 non-rotatably connected to cover 102; and at least one impeller blade 118. Turbine 106 includes: turbine shell 120 non-rotatably connected to hub 110; and at least one turbine blade 122. Lock-up clutch 108 includes piston plate 124. Torque converter 100 includes: apply chamber 126; release chamber 128; and chamber 130. By “non-rotatably connected” components, we mean that: the components are connected so that whenever one of the components rotate, all the components rotate; and relative rotation between the components is not possible. Radial and/or axial movement of non-rotatably connected components with respect to each other is possible, but not required.

Flow plate 112 is non-rotatably connected to seal plate 114. For example, flow plate 112 may be fixed to seal plate 114 by weld 132 at a radially outer end. However, it is to be understood that other connection methods may be employed, such as use of an O-ring, steel-steel connection, or a gasket. Chamber 126 is bounded, at least in part, by piston plate 124 and seal plate 114. Chamber 128 is bounded, at least in part, by cover 102, seal plate 114, and piston plate 124. Chamber 130 is bounded, at least in part, by seal plate 114 and shell 116. By “bounded in part,” we mean that a portion of the cited chamber, flow path, or other structure is bounded, or formed, by the cited element.

Seal plate 114 includes through-bore 134 bounded in opposite radial directions RD1 and RD2, orthogonal to axis AR, by seal plate 114. Through-bore bore 134 is further defined by flow plate 112 and is also bounded in opposite radial directions RD1 and RD2 by flow plate 112. In an example embodiment: torque converter 100 includes rivet 136 connecting seal plate 114 and flow plate 112, wherein through-bore 134 passes through, or is defined within, rivet 136. Torque converter 100 includes flow path 138 and flow path 140. Flow path 140 is sealed from flow path 138 and includes, that is, passes through, through-bore 134. That is, flow path 140 includes through-bore 134. Flow path 138 does not pass through through-bore 134. Flow path 140 further includes, that is, passes through opening 142 defined in hub 110. That is, pressurized fluid may flow through opening 142 and through-bore 134 into chamber 128. Flow path 140 may further be bounded, at least in part, by flow plate 112 and hub 110. Flow path 138 is bounded, at least in part, by seal plate 114 and flow plate 112. That is, flow path 138 passes or flows between seal plate 114 and flow plate 112. Seal plate 114 and/or flow plate 112 may include grooves for flow therebetween. Flow path 138 passes through opening 144 defined in seal plate 114 that opens into apply chamber 126. That is, pressurized fluid may be supplied from transmission input shaft 143 to flow path 138 extending between seal plate 114 and flow plate 112 through opening 144 into apply chamber 126. In this way, flow path 138 includes, and passes through, opening 144.

For a lock-up mode for torque converter 100, in which piston plate 124 is non-rotatably connected to cover 102 and the torque is transmitted to hub 110 through clutch 108, Pressurized fluid is arranged to flow through flow path 138, and passing through opening 144, into apply chamber 126 to displace piston plate in axial direction AD1 to connect piston plate 124 with cover 102 bypassing the hydrodynamic fluid coupling. For a torque converter mode for torque converter 100, in which cover 102 is rotatable with respect to piston plate 124 and the torque bypasses clutch 108, pressurized fluid is arranged to flow through flow path 140, including passing through opening 142 and through-bore 134, into release chamber 128 to displace piston plate 124 in axial direction AD2, opposite direction AD1, to disconnect piston plate 124 from cover 102.

In an example embodiment, torque converter 100 includes seals 146, 148. Seal 146 seals an outer diameter of seal plate 114 to an outer end of piston plate 124 and seal 148 seals an inner diameter of piston plate 124 to seal plate 114. Seal plate 114 is disposed, at least partially, axially between piston plate 124 and turbine shell 120. Seal plate 114 further includes a portion axially aligned with piston plate 124. That is, a line orthogonal to axis of rotation AR and passing through that portion of the seal plate would also pass through a portion of piston plate 124. Piston plate 124 is further connected to seal plate 114, for example, by connection 150, which may be a leaf-spring and/or riveted connection. Seal plate 114 may further be connected to an inner diameter or end of cover 102. Flow plate 112 may further be piloted on input shaft 143 via bushing 152.

In an example embodiment, torque converter 100 includes: stator 160 with at least one stator blade 162; one-way clutch 164; torsional vibration damper 166; and pendulum vibration absorber 168. Damper 166 includes input plate 170, at least one spring 172, spring retainer plate 174, at least one spring 176, and output flange 178. Spring 172 is engaged with plates 170 and 174. Spring 176 is engaged with plate 174 and flange 178. Absorber 168 is connected to plate 174 and flange 178 is connected to hub 110. Flange 178 may be formed integrally with hub 110. That is, flange 178 and output hub 110 may be formed as a single piece. Turbine shell 120 may be connected to flange 178, for example, via a riveted connection. Plate 174 may be centered on flange 178 and washer 180 may be disposed between flow plate 112 and plate 174 and clipped to plate 174.

In an example embodiment, clutch 108 includes clutch plate 186 axially disposed between cover 102 and piston plate 124. Clutch plate 186 is non-rotatably connected to plate 170 and connected to spring 172. Friction material 188 may be disposed between, and affixed to one of, cover 102 and clutch plate 186. Friction material 190 may be disposed between, and affixed to one of, clutch plate 186 and piston plate 124.

Embodiments according to the present disclosure provide various advantages including cost reductions by creating a cross flow configuration without any forgings or costly cross drilling operations.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the disclosure that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, to the extent any embodiments are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments are not outside the scope of the disclosure and can be desirable for particular applications.

LIST OF REFERENCE NUMBERS

-   -   100 torque converter     -   102 cover     -   104 impeller     -   106 turbine     -   108 lock-up clutch     -   110 output hub     -   112 flow plate     -   114 seal plate     -   116 impeller shell     -   118 impeller blade     -   120 turbine shell     -   122 turbine blade     -   124 piston plate     -   126 apply chamber     -   128 release chamber     -   130 chamber     -   132 weld     -   134 through-bore     -   136 rivet     -   138 flow path     -   140 flow path     -   142 opening     -   143 transmission input shaft     -   144 opening     -   146 seal     -   148 seal     -   150 connection     -   152 bushing     -   160 stator     -   162 one stator blade     -   164 one-way clutch     -   166 torsional vibration damper     -   168 pendulum vibration absorber     -   170 input plate     -   172 spring     -   174 spring retainer plate     -   176 spring     -   178 output flange     -   180 washer     -   186 clutch plate     -   188 friction material     -   190 friction material 

What is claimed is:
 1. A torque converter, comprising: a cover arranged to receive torque; an impeller having an impeller shell non-rotatably connected to the cover; a turbine in fluid communication with the impeller and including a turbine shell; a lock-up clutch including a piston plate; an output hub connected to the turbine shell and arranged to non-rotatably connect to a transmission input shaft; a seal plate disposed, at least partially, axially between the piston plate and the turbine shell, wherein the seal plate is connected to the cover and the piston plate, wherein the seal plate includes a first axial side facing the piston plate and a second axial side facing the turbine shell, wherein an opening extends axially through the first and second axial sides of the seal plate; a flow plate connected to the seal plate at a location radially outward of the opening and disposed axially between the seal plate and the turbine shell, wherein a portion of the flow plate is radially aligned with the opening such that fluid can be routed therebetween; and a through-bore bounded in first and second opposite radial directions by the seal plate, wherein a first chamber is bounded at least in part by the piston plate and the seal plate and a second chamber is bounded at least in part by the cover, the seal plate, and the piston plate.
 2. The torque converter according to claim 1, further comprising: a first flow path configured to provide fluid to the first chamber, wherein the first flow path includes a portion bounded in part by the seal plate and the flow plate; and a second flow path configured to provide fluid to the second chamber, wherein the second flow path passes through the through-bore and includes a portion bounded in part by the flow plate and the output hub.
 3. The torque converter according to claim 2, wherein the first flow path is sealed from the second flow path.
 4. The torque converter according to claim 2, wherein the first flow path does not pass through the through-bore.
 5. The torque converter according to claim 2, wherein the first flow path passes through the opening into the first chamber.
 6. The torque converter according to claim 2, wherein the output hub includes a further opening extending axially therethrough and the second flow path passes through the further opening.
 7. The torque converter according to claim 2, wherein for a lock-up mode the piston plate is non-rotatably connected to the cover and pressurized fluid is arranged to flow through the first flow path into the first chamber to displace the piston plate in an axial direction toward the cover.
 8. The torque converter according to claim 2, wherein for a torque converter mode pressurized fluid is arranged to flow through the second flow path passing through the through-bore into the second chamber to displace the piston plate in an axial direction away from the cover to disconnect the piston plate from the cover.
 9. The torque converter according to claim 1, wherein the opening is radially outside of the through-bore.
 10. The torque converter according to claim 1, wherein an inner end of the cover is connected to the seal plate.
 11. The torque converter according to claim 1, wherein the seal plate is connected to the piston plate at an outer diameter thereof.
 12. A torque converter, comprising: a cover arranged to receive torque; an impeller having an impeller shell non-rotatably connected to the cover; a turbine in fluid communication with the impeller and including a turbine shell; a lock-up clutch including a piston plate; an output hub connected to the turbine shell and arranged to non-rotatably connect to a transmission input shaft; a seal plate disposed, at least partially, axially between the piston plate and the turbine shell, wherein the seal plate is connected to the cover and the piston plate, wherein the seal plate includes a first axial side facing the piston plate and a second axial side facing the turbine shell, wherein an opening extends axially through the first and second axial sides of the seal plate; a flow plate connected to the seal plate at a location radially outward of the opening and disposed axially between the seal plate and the turbine shell, wherein a portion of the flow plate is radially aligned with the opening such that fluid can be routed therebetween; and a through-bore bounded in first and second opposite radial directions by the seal plate, wherein a first chamber is bounded at least in part by the piston plate and the seal plate and a second chamber is bounded at least in part by the cover, the seal plate, and the piston plate; wherein: a first flow path is fluidly connected to the first chamber, the first flow path including a portion bounded in part by the seal plate and the flow plate; and a second flow path is fluidly connected to the second chamber and sealed from the first flow path, wherein the second flow path passes through the through-bore.
 13. The torque converter according to claim 12, wherein for a lock-up mode the piston plate is non-rotatably connected to the cover and pressurized fluid is arranged to flow through the first flow path into the first chamber to displace the piston plate in a first axial direction toward the cover.
 14. The torque converter according to claim 13, wherein for a torque converter mode pressurized fluid is arranged to flow through the second flow path passing through the through-bore into the second chamber to displace the piston plate in a second axial direction away from the cover to disconnect the piston plate from the cover.
 15. The torque converter according to claim 12, wherein the output hub includes a further opening extending axially therethrough, the second flow path passes through the further opening, and the second flow path includes a portion bounded in part by the flow plate and the output hub.
 16. The torque converter according to claim 12, wherein the first flow path passes through the opening into the first chamber.
 17. The torque converter according to claim 12, wherein the seal plate is sealed to the piston plate at an outer diameter thereof and sealed to an inner end of the piston plate.
 18. The torque converter according to claim 17, wherein an inner end of the cover is fixed to the seal plate.
 19. The torque converter according to claim 12, wherein a rivet connects the seal plate with the flow plate and the through-bore is defined within the rivet. 